Package with folded handle and method for making same

ABSTRACT

The present invention is directed to a package with a folded handle and methods for making the same. One aspect of the invention includes a package including a front panel joined at respective opposite side edges to a rear panel to form a package having an interior and an exterior. The package has a folded handle formed by folding a plurality of marginal portions of the package in the direction of the front panel and joining at least one of the marginal portions to the front panel substantially along a seam extending transversely across the package, though not along at least one non-joined portion provided along the seam. The non-joined portion or portions of the seam provide access to at least one pocket defined by the at least one marginal portion and the front panel. The pocket or pockets can receive a user&#39;s hand or hands so that the user can grip the package.

FIELD OF THE INVENTION

The present invention relates generally to packages with handles. More specifically, the present invention relates to a bag with a folded handle and methods of making the same.

BACKGROUND OF THE INVENTION

Conventionally, handles for packages, such as bags made from thermoplastic polymers used to store and carry vended goods, have been either die cut, die cut with a reinforcement, or separately fabricated and attached to a bag, either mechanically or by heat sealing.

Die cut handles comprise a cut that is formed in the substrate of the bag. Such a handle is inexpensive, but reduces the capacity of the bag and often does not provide sufficient strength when substantial weights are placed in the bag. Reinforced die cut handles are of a folded form that is heat sealed to the rim of the die cut slot in the bag. Such a handle has adequate shear strength, but the cost of the reinforcement is sometimes as high as the cost of the bag itself. Separately fabricated handles provide sufficient strength to withstand substantial weights, but such handles are often difficult to attach to bags and they increase manufacturing costs, including costs associated with the separate manufacturing steps of fabricating the handle and affixing the handle to the bag.

Many types of bags with handles are provided in the prior art. For example, U.S. Patent No. 2,339,304 discloses a sealed bag having an external pocket for receiving a hook on a display rack. The upper marginal edge of a bag is sealed all the way across from one edge of the bag to the other. The seal tightly encloses the contents within the bag. The upper marginal portion is folded back upon itself, and pressure and heat is applied to the marginal portion to seal four thicknesses of the substrate of the bag. The pocket is provided by separating two thicknesses of substrate, so that adjacent sides of the thicknesses are not sealed together.

U.S. Pat. No. 3,774,837 provides a carrying bag with a handle. At the open end of the bag, reinforcing folds or strips extend transversely across the bag and are welded to the wide sides of the bag by weld seams extending obliquely towards the opening edge. Grip openings are punched out in the center of the opening edge and are formed by the center part of the reinforcing folds or strips between two inclined weld seams. The carrier bag can be easily kept completely open due to the position of the carrying grips.

U.S. Pat. No. 3,858,789 provides a plastic bag with a folded handle. A flap adjacent to the top of the bag is folded over and against a rear wall of the bag. After the flap is folded, a pair of convergently angled heat seals is formed at the top of the bag. The heat seals project at 45° angles that are angled toward each other, but do not meet. The heat seals extend beyond the lower edge of the flap, thus sealing a portion of the front wall of the bag to a portion of the rear wall of the bag together below the lower edge of the flap. The heat seals in combination with the flap and front and rear walls form a pocket that serves as a carrying handle for the bag. Optionally, a heat seal can be used to completely seal the bag.

U.S. Pat. No. 3,985,290 discloses a folded handle for a bag, the handle being formed from a sheet of material. The handle is made separately from the bag and secured to the top of the bag by staples after the bag is manufactured. The handle forms a pocket with tapered sides to permit the stacking of a plurality of handles prior to affixing the handles to bags. The upper end of the bag need not be sealed or closed before the handle is attached to the bag.

U.S. Pat. No. 6,146,016 provides a handle closure system for a bag. The handle closure system includes a first closure element and a second closure element, preferably made of hook and loop material, where at least one of the closure elements includes a cut-out opening, and, preferably, both closure elements include matching cut-out openings. The cut-out openings may be in a variety of shapes, with an arc or elongated oval shape preferred. The first closure element is placed adjacent an opening of a bag and the second closure element is displaced from the opening such that when the bag portion adjacent the opening is folded down, the first and second closure elements mate with the cut-out openings, aligning substantially to form a handle with a resulting notch for accommodating a user's fingers.

In many prior art constructions, heat seals are used to weld multiple substrate layers together to seal the bag or provide reinforcing support for carrying the bag via a handle. Many prior art constructions have only a single folded-over portion at the end of a bag in combination with a heat seal to seal the contents within the bag. Further, a number of prior art constructions employ cuts or cut-outs in the substrate to form handles or grips.

There remains a need for a folded package handle formed integrally with the package that is durable, inexpensive, easy to manufacture, and strong enough to support substantial weight; that provides an opportunity for material savings; and that sufficiently seals the contents of the bag without decreasing the capacity of the bag considerably. A folded package handle that does not require, though may permissibly incorporate, the use of heat seals is also desired for application to bags made of substrates that are not susceptible to heat sealing and for ease of manufacture on equipment that does not include means for making heat seals.

SUMMARY OF THE INVENTION

The present invention is directed to a package with a folded handle and methods for making the same. One aspect of the invention includes a package including a front panel joined at respective opposite side edges to a rear panel to form a package having an interior and an exterior. The package has a folded handle formed by folding a plurality of marginal portions of the package in the direction of the front panel and joining at least one of the marginal portions to the front panel substantially along a seam extending transversely across the package, though not along at least one non-joined portion provided along the seam. The non-joined portion or portions of the seam provide access to at least one pocket defined by the at least one marginal portion and the front panel. The pocket or pockets can receive a user's hand or hands so that the user can grip the package.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiments of the invention which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:

FIG. 1 is a side isometric view of a package with folded handle in accordance with an embodiment of the invention;

FIG. 2 is a side isometric view of the package of FIG. 1 with an unfolded top portion;

FIG. 3 is a front elevational view of the package of FIG. 2 with a portion of the package in an unfolded, open position;

FIG. 4 is a front elevational view of the package of FIG. 3 after a first fold has been made;

FIG. 5 is a front elevational view of the package of FIG. 4 after a second fold has been made and the last folded-over portion is joined to the front panel of the package;

FIG. 6 is a cross-sectional view of FIG. 5 showing the folded-over portions where the last folded-over portion is joined to the front panel of the package.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The description of preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “joined,” “connected,” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

Referring to FIG. 1, an embodiment of the invention includes a package 10. Package 10 includes a front panel 12, a rear panel 14, and a folded handle 16.

Package 10 includes a front panel 12 and a rear panel 14 each with a bottom edge 19, side edges 20, and a top edge 21. In some embodiments, the respective opposite edges 20 of front panel 12 and rear panel 14 are joined directly. In other embodiments, the respective opposite side edges 20 of front panel 12 and rear panel 14 are joined via a side gusset 22 (a fold/crease that gives the bag a three-dimensional shape). Side gusset 22 initially projects inwardly between front panel 12 and rear panel 14 and allows package 10 to expand in volume. Side gussets 22 are typically formed integrally with the front and rear panels. Front panel 12 and rear panel 14 may be manufactured integrally as a continuous substrate suitably folded and joined to itself with a longitudinal seam in a tube-like configuration. Alternatively, front panel 12 and rear panel 14 may be manufactured separately as independent films or sheets of substrate to be joined at their respective opposite edges. Bottom edge 19 of front panel 12 is joined to bottom edge 19 of rear panel 14. When the front and rear panels are joined at their respective opposite side edges 20 and bottom edges 19, the panels form a bag or pouch defining an interior space. The top portions 21 of the front and rear panels define a mouth or opening 23. See FIGS. 2-4. Opening 23 communicates with and provides access to the interior of package 10.

Front panel 12 and rear panel 14 can be made from any variety of substrates suitable for packaging, wrapping, covering, casing, or encasing materials. Conventionally, packages have been composed of multiple layers of paper and solid plastic films with an outer ply typically including a polymer-coated paper with a smooth printing surface, wherein the paper may be laminated to a layer of film and another paper layer. Some embodiments provide a package comprising a middle layer of woven mesh tubing to which an outer layer of solid plastic film is adhered using polypropylene or other polylaminates. The outside layer of film (comprising the outside of the package) may be printed or reverse-printed with graphics and product labeling. Solid films are utilized, which provide excellent printability and strength and meet or exceed performance standards dictated by the marketplace. Some embodiments also use films that are treated or coated to prevent slippage of packages during manufacturing, filling, transport, and storage. The materials to be used may partially or wholly comprise compostable, degradable, or recyclable materials. In some embodiments, a package is provided in the form of a multi-layered composite bag used to store bulk-type products such as pet food, seeds, fertilizer, cereals, grains and other bulk products intended for human and non-human consumption.

In some embodiments wherein front panel 12 and rear panel 14 are manufactured integrally, a woven mesh material is formed into a tube to which a sheet of plastic film is adhered using a lamination process. The mesh material is comprised of suitable film-forming plastic resin that is split and/or stretched and then woven to form a mesh or net-like material. The woven mesh material is formed into a tubular shape to easily adapt to high-speed bag-forming equipment. The tube, which is flattened and gusseted, is then fed into a laminator with two extruders, and laminated on both sides of the flattened tube to a solid plastic film using polypropylene or other polylaminate.

Among the alternative films that can be employed in making the mesh tubes are, without limitation, thermoplastic synthetic polymers, including polyolefins such as low density polyethylene, linear low density polyethylene, polypropylene coated with a layer of polyethylene, high density polyethylene, metallocene, electron-beam cured solid films, copolymers of ethylene and propylene and combinations of these polymers, polyesters, polyamides, polyvinyl polymers, and copolymers, and polylactic acid (PLA) resins. Preferred resins are polyethylene, low density, high density, or linear low density, and combinations thereof, as well as polypropylene coated or laminated with a layer of polyethylene, and polyesters. The solid plastic film to which the mesh tubes are adhered are comprised of various thermoplastic resins or polymers or combinations thereof, including but not limited to, low density polyethylene, high density polyethylene, linear low density polyethylene, metallocene, and/or polypropylene coated with a layer of polyethylene, films coated with electron-beam surfaces that may or may not be pre-printed, and PLA resins.

An outer solid plastic film layer provides a surface for printing or reverse-printing graphics and/or product labeling. The outer solid plastic film is then adhered to the mesh tubes using adhesives, laminating using nip rollers, poly extrusion laminating, or some other known means of attaching the two layers. The mesh tube comprises the inside layer of the package, giving the package strength and integrity. Alternatively, a layer of transparent or colored film may serve as an inside liner of the package and may or may not be printed. In such an embodiment, the package has three layers: (a) an outer polymeric solid film layer; (b) a middle polymeric mesh woven layer, and (c) an inner polymeric solid film layer. The outside film layer is also treated or otherwise coated on one side with any material that alters the level of slipperiness or tackiness of the outer surface, including the static coefficient of friction measure, making the package less likely to slip during manufacturing, transporting and/or storing.

In an embodiment wherein front panel 12 and rear panel 14 are manufactured as separate films to be joined, the respective opposing side and bottom edges of front panel 12 and rear panel 14 may be joined by any number of various methods of sealing and shutting packages, including, but not limited to, using adhesives or heat seals.

In some embodiments, the folded handle 16 is formed by folding a plurality of marginal portions at the top of the front and rear panels from rear panel 14 toward the direction of front panel 12. The penultimate folded-over marginal portion is joined to the front panel 12 substantially along seam 50 but not along at least one non-joined portion 52. In the vicinity of each non-joined portion 52, a pocket or handle 54 defined by first marginal portion 46, second crease 44, and front panel 12 is formed. The pocket 54 can receive the digits of a user's hand so that the user can grip package 10.

From the foregoing description, assembly and use of an exemplary package will be readily apparent. Referring to FIGS. 2-5, one embodiment of package 10 is folded and closed in the following manner. Front panel 12 and rear panel 14 are flattened or pressed together and a first marginal portion 46 (e.g., the top or distal portion of the package 10) of package 10 is rolled or folded in the direction of front panel 12 such that top edge 21 of front panel 12 is folded down toward front panel 12 and a first crease 40 is made transversely across the top of package 10. By folding over a first marginal portion 46 along a first crease 40, the package can be initially sealed so that the contents of the package cannot fall out of the interior of the package through opening 23. After first crease 40 is formed, a second marginal portion 42 (e.g., the penultimate portion of the package, immediately adjacent to the first marginal portion) of package 10 is rolled or folded in the direction of front panel 12, such that first crease 40 is folded down toward front panel 12 and a second crease 44 is made transversely across the top of package 10. Pressure can be applied to the folded-over marginal portions after each or both of first crease 40 and second crease 44 in order to sharpen or strengthen the creases and provide a stronger or tighter seal of package 10. Once second crease 44 is formed and first marginal portion 46 contacts front panel 12, first marginal portion 46 is joined to front panel 12 substantially transversely across package 10 substantially along seam 50. At least one non-joined portion 52 of the first marginal portion 46 is not joined to front panel 12, thereby forming at least one opening to at least one pocket or handle 54 defined by first marginal portion 46, second crease 44, and front panel 12. Each pocket 54 can receive the digits of a user's hand so that the user can grip package 10. Specifically, to grip the package, the user inserts four digits into pocket 54 such that the tips of the user's fingers make contact with the first marginal portion 46 defining the interior of pocket 54 and the user's hand wraps around second crease 44 at the top of sealed package 10 such that the user's thumb makes contact with rear panel 14. In some embodiments, a single non-joined portion 52 is provided with sufficient length and a single pocket 54 is sufficiently large to receive two of the user's hands, or eight digits. In some embodiments, a single non-joined portion 52 and a single pocket 54 are provided substantially centered between opposite side edges 20 of said front panel 12. In other embodiments, more than one non-joined portion 52 provide access to more than one pocket 54 such that each pocket may receive a user's hand.

The first marginal portion 46 and front panel 12 may be joined along seam 50 by any suitable means, including, for example, use of welding, bonding, stitching or sewing, or any of a variety of adhesives, binders, heat seals, cold seals, or any other joining means. In some embodiments, an adhesive such as a glue is used to join the first marginal portion and the front panel. Preferably, after first crease 40 is formed and while second crease 44 is being formed, glue is applied either to front panel 12 or to first marginal portion 46 by a programmable glue nozzle machine such as, for example, a BOSCH® DOBOY® GS-1000 bag gluer-sealer. In some embodiments, a programmable glue nozzle machine applies a single, straight, continuous bead of glue substantially along seam 50 from one side edge 20 of front panel 12 approximately one third (⅓) of the way transversely across front panel 12, the glue nozzle applies no glue along non-joined portion 52, which is near or around an approximate middle one third (⅓) of the transverse length of front panel 12, and the glue nozzle machine applies a single, straight, continuous bead of glue substantially along seam 50 near or around a final one third (⅓) of the transverse length of front panel 12 from the end of non-joined portion 52 to an opposite side edge 20. In some embodiments, the programmable glue nozzle may be adjusted to apply different types, amounts, or patterns of glue. For example, in some embodiments, different types of glue may be used (e.g., a cold melt resin glue or a hot melt glue). A thicker or thinner bead of glue may be applied (e.g., a bead one eighth (⅛) inches in thickness or a bead one quarter (¼) inches in thickness). The glue may be applied across more than or less than a combined two thirds (⅔) of the front panel (e.g., across two (2) one quarter (¼) lengths near the opposite side edges 20, with non-joined portion 52 extending over a middle half (½) length across the package). More than one single, straight, continuous bead of glue may be applied (e.g., two parallel, straight, continuous beads of glue). And, one or more non-straight beads of glue (e.g., a wavy line or a series of overlapping circles) or non-continuous beads of glue (e.g., a dashed or dotted line or other non-continuous pattern) may be applied. In these different embodiments, the type, pattern, and amount of glue applied may be variable based on, for example, the material used for the substrate of the package and/or the weight of the intended contents of the package. The glue may be applied by a programmable glue nozzle machine either by moving the package with respect to the glue nozzle or by moving the glue nozzle with respect to the package.

When joining means of suitable strength are used to join first marginal portion 46 and front panel 12, the strength of folded handle 16 is at least as great as the tensile strength of the substrate material. Because there are no cuts or cut-outs used to form folded handle 16, the strength of the handle is not dependent on the shear strength of the substrate material. The strength of the handle will depend largely on the strength of the joining means used to join first marginal portion 46 and front panel 12, particularly in the vicinity of the areas immediately surrounding either end of non-joined portion 52. When the package is loaded with contents and gripped by the folded handle, the concentration of tensile forces caused by the weight of the contents will be in the areas immediately surrounding the ends of non-joined portion 52. For this reason, the suitability of joining means used to join first marginal portion 46 and front panel 12 will be affected by the weight of the intended contents of package 10.

In some embodiments, multiple folds and creases (e.g., more than two) may be implemented to close package 10. For example, in some embodiments, two folds forming two creases may be implemented before a third fold brings a penultimate marginal portion in contact with front panel 12.

First marginal portion 46 and second marginal portion 42 may be of any width or widths suitable for folding and sealing package 10. Preferably the marginal portions are each about ½ (0.5) inches to about 2 inches, and most preferably the marginal portions are each about 1¼ (1.25) inches. First marginal portion 46 may or may not have a width equal to the width of second marginal portion 42.

In some embodiments, there is a single non-joined portion 52. The single non-joined portion 52 may be of any length suitable for allowing pocket 54 to receive a hand. Preferably, non-joined portion 52 is about 3 inches to about 6 inches in length, and most preferably non-joined portion 52 is about 4 inches in length.

In some embodiments, seam 50 has a width that is substantially less than the width of said first marginal portion 46. For example, in some embodiments, first marginal portion 46 has a width of about 1¼ (1.25) inches and seam 50 has a width of about ⅛ (0.125) inches to ¼ (0.25) inches. In some embodiments, seam 50 is provided substantially adjacent to first crease 40. In other words, seam 50 is provided closer to first crease 40 than to second crease 46.

In some embodiments not pictured in FIGS. 1-6, folded handle 16 can be applied to both the top and bottom ends of package 10. Folded handles applied at opposite ends of the package can be positioned on the same or opposite sides (panels) of the package.

In some embodiments, package 10 is loaded with contents via the end of the package opposite the end containing folded handle 16. In this way, package 10 can be manufactured with folded handle 16 at one end of the package and the opposite end of the package can be left open and/or unsealed. The package can thus be conveniently and economically manufactured, stored, sold, and shipped substantially flat. Subsequently, the package can be filled with contents at the open end and the open end can thereafter be closed and/or sealed in accordance with the present invention or by other means. In other embodiments, package 10 is closed or sealed at one end, filled with contents at the opposite, open end, and that opposite end is then closed or sealed in accordance with the present invention to fabricate folded handle 16.

It is to be understood that the present invention is by no means limited only to the particular constructions herein disclosed and shown in the drawings. The appended claims should be construed broadly to cover any variations or modifications within the scope or range of equivalents of the claims. 

1. A package comprising: a front panel and a rear panel joined at respective opposite side edges thereof to said front panel to form a package having an exterior; and a folded handle comprising a plurality of marginal portions of said package folded in the direction of said front panel, wherein at least one of said plurality of marginal portions is joined to said front panel substantially along a seam extending transversely across said package, and at least one non-joined portion provided along said seam provides access to at least one pocket defined by said at least one of said plurality of marginal portions and said front panel, whereby a hand may be inserted in said at least one pocket in order to grip said package.
 2. The package of claim 1, wherein said at least one of said plurality of marginal portions is joined to said front panel by at least one of an adhesive, a binder, a heat seal, a cold seal, a stitch, and a fastener.
 3. The package of claim 1, wherein said at least one of said plurality of marginal portions is joined to said front panel by a non-continuous bead of a glue.
 4. The package of claim 1, wherein said at least one non-joined portion has a length of from about 3-6 inches.
 5. The package of claim 1, wherein each marginal portion of said plurality of marginal portions has a width of from about 0.5-2 inches.
 6. The package of claim 1, wherein there is provided one non-joined portion of said seam centered substantially between said opposite side edges.
 7. The package of claim 1, wherein said package comprises a composite bag including a woven mesh tube, a layer of polylaminate on both sides of said tube, and a layer of solid plastic film adhered to both sides of said tube.
 8. A package comprising: a front panel and a rear panel joined at respective opposite side edges thereof to said front panel to form a package having an exterior, wherein a top edge of said joined front and rear panels defines an opening; and a folded handle comprising a plurality of marginal portions including a first marginal portion adjacent to said top edge, wherein said first marginal portion is folded in the direction of said front panel along a first crease to seal said opening, and each marginal portion of said plurality of marginal portions is folded in the direction of said front panel such that at least one of said plurality of marginal portions faces said front panel and is joined to said front panel substantially along a seam extending transversely across said package, wherein provided along said seam is at least one non-joined portion where said at least one of said plurality of marginal portions is not joined to said front panel, and said at least one non-joined portion provides access to at least one pocket defined by said at least one of said plurality of marginal portions and said front panel, whereby a hand may be inserted in said pocket in order to grip said package.
 9. The package of claim 8, wherein said first marginal portion is joined to said front panel substantially along said seam.
 10. The package of claim 9, wherein a width of said seam is substantially less than a width of said first marginal portion and said seam is provided substantially adjacent to said first crease.
 11. The package of claim 10, wherein said first marginal portion is joined to said front panel by joining means.
 12. The package of claim 10, wherein said first marginal portion is joined to said front panel by a non-continuous bead of a glue.
 13. The package of claim 9, wherein there is provided one non-joined portion of said seam providing access to only one pocket and said non-joined portion and said pocket are centered substantially between said opposite side edges.
 14. The package of claim 8, wherein said package comprises: (a) a layer of polymeric solid film and (b) a layer of polymeric mesh woven fabric, wherein a tie resin material added during manufacture of said package adheres (a) to (b)
 15. The package of claim 8, wherein said package comprises at least one first layer of polymeric solid film adhered to a layer of polymeric mesh woven fabric via a tie resin material and at least one second layer of polymeric solid film adhered to said layer of polymeric mesh woven fabric via said tie resin material.
 16. A method for manufacturing a package which comprises: (a) providing a packaging substrate including a front panel, a rear panel and a top edge defining an opening; (b) folding at least one first marginal portion of said rear panel in the direction of said front panel so as to seal said opening; (c) folding a second marginal portion of said rear panel in the direction of said front panel; and (d) joining said at least one first marginal portion to said front panel substantially along a seam extending transversely across said package, while not along at least one non-joined portion provided along said seam.
 17. The method of claim 16, wherein said at least one first marginal portion is joined to said front panel by applying joining means to said front panel.
 18. The method of claim 16, wherein said at least one first marginal portion is joined to said front panel by applying joining means to said at least one first marginal portion.
 19. The method of claim 16, further comprising applying pressure over said second marginal portion to secure the joining of said at least one first marginal portion to said front panel.
 20. The method of claim 16, wherein (d) comprises applying a glue to at least one of said at least one first marginal portion and said front panel via a programmable glue nozzle machine. 